5041228 EVINRUDE GROMMET SHIFT ROD

START BY:a) remove fuel injection pump housing and governorb) remove governorc) remove fuel transfer pumpd) remove fuel injection pumps The disassembly and assembly of all the different combinations of fuel injection pump housings for the 3408 and 3412 Generator Sets are similar so only one will be shown. The minor differences will be shown. Steps 1 and 2 are for fuel injection pump housings that use a Woodward PSG governor.1. Remove wire (1) and cover (2) from the fuel injection pump housing. 2. Remove screw (5), nut (6) and the lock and washer under the nut. Remove cover (4).3. Remove housing (3) from the fuel injection pump housing. 4. Remove shaft (7) from housing (3). 5. Remove bearing (8) from the housing. Steps 6 through 8 are for fuel injection pump housings that use a Woodward PSG governor.6. Remove bolt (9), lever (11) and shaft and lever (10) from the fuel injection pump housing. 7. Put a mark on shaft (13) and lever (10) as to the location of the lever on the shaft. Remove bolt (12). Remove lever (10) from shaft (13). 8. Remove bolts (15) and (16). Move shaft (19) to the right until it is out of the fuel injection pump housing. Remove levers (14) and (20) as the shaft is removed from the fuel injection pump housing.9. Remove the bolts, retainer (17) and gear (18). Step 10 is for fuel injection pump housings that use a Woodward PSG governor.10. Remove ring (21), washer (22) and pinion (24) from the fuel injection pump housing. Remove adapter (23). 11. Remove the adapter over the gear and pinion. Remove gear (25). Hit the end of pinion (26) to remove it from gear (27). Remove pinion (26) and gear (27) from the fuel injection pump housing. 12. Remove bolt (29), bracket assembly (30) and link (28). 13. Pull the end of spring (33) out away from bracket (34). Remove pin (31), lever (32) and spring (33) from bracket (34). 14. Remove two racks (36) from the fuel injection pump housing. Step 15 is for fuel injection pump housings that use a Woodward PSG governor.15. Remove plug (35). Remove the O-ring seal on the plug. Fuel Injection pump housings that use a dashpot type governor will have valve (37) and not plug (35).16. Remove valve (37) from the fuel injection pump housing. 17. Remove two O-ring seals (41) from valve (37). Push in on piston (39). Remove pin (38). Remove piston (39) and spring (40) from valve (37). 18. Put identification on each lifter as to its location in the fuel injection pump housing. Remove lifters (42) from the fuel injection pump housing.19. Remove camshaft (43). 20. Use tooling (A) to remove dowel (44) and shaft (46). Use tooling (B) to remove two bearings (47) and two bearings (48) from the fuel injection pump housing. Remove pin (45). 21. Use tooling (C) to remove rack bearings (48) from the fuel injection pump housing. 22. Use tooling (D) to remove the camshaft bearings from the fuel injection pump housing.Assemble Fuel Injection Pump Housing
1. Use tooling (A) as shown to install the camshaft bearings in the fuel injection pump housing. Before the bearings are installed, see the next illustration. 2. Install the bearings in the fuel injection pump housings so that the bearing oil hole is in area (V). The bearing joint must be in area (W).3. Install front bearing (1) in the fuel injection pump housing so that it is 1.0 0.5 mm (.040 .020 in.) into the housing. 4. Install rear bearing (4) so that is is 4.8 0.5 mm (.189 .020 in.) below surface (2). On fuel injection pump housings from a 3412 Generator Set, install bearing (3) so that it is 127.0 0.5 mm (5.000 .020 in.) below surface (2).5. Put clean engine oil on the inside diameter of each bearing. 6. Install tool (B) on the fuel injection pump housing as shown. Install the rack bearing in tool (B). Install the end of the bearing with the notch first. Use tool (C) to install the bearing in the fuel injection pump housing. The bearing will be installed to the correct depth when tool (C) comes in contact with tool (B).7. Do Step 6 again for the other rack bearing. Steps 8 through 12 are for fuel injection pump housings that have a Woodward PSG governor.8. Use tooling (D) to install the inner bearing in the fuel injection pump housing. Install the bearing so that dimension (X) is 73.03 0.57 mm (2.875 .020 in.).9. Use tooling (D) to install the outer bearing. Install the bearing so that dimension (Y) is 34.80 0.51 mm (1.370 .020 in.).10. Use tooling (D) to install the lip type seal next to the inner bearing. Install the seal with the lip out as shown. Install the seal even with the surface.11. Use tooling (F) to install the lip type seal against the outer bearing. Install the seal with the lip out as shown.12. Put clean engine oil on the lip of each seal.13. Install shaft (5) in the fuel injection pump housing. Install the shaft so that it extends 16.8 0.5 mm (.661 .020 in.) above surface (6).14. Use tooling (E) to install the lower bearing in the fuel injection pump housing. The bearing must be installed with the end of the bearing with the chamfer toward the inside. See the next illustration for the correct location of the notch in the bearing. 15. A centerline drawn through the notch as shown must make a 10° 5° angle with the horizontal centerline as shown. Install the lower bearing so that the top of the lower bearing is 28.4 0.5 mm (1.118 .020 in.) below the surface. 16. Use tooling (F) to install bearing (9). See the previous illustration for the correct location of the notch in the bearing. The end of the bearing with the chamfer must